24V vs 36V vs 48V Robot Battery: How to Choose the Right Voltage

Choosing the correct battery voltage is an important part of robot power system design. For AGVs, AMRs, cleaning robots, inspection robots, warehouse robots, and other mobile equipment, 24V, 36V, and 48V battery systems are commonly considered during product development.

However, battery voltage should not be selected simply by comparing numbers. The motor, controller, power consumption, operating time, peak current, installation space, charging system, BMS, and communication requirements all need to work together.

For OEM and ODM projects, the battery pack should be designed around the actual operating conditions of the robot.

Dongguan Yizhan Electronics Technology Co., Ltd. provides customized lithium battery pack solutions for robots, AGVs, AMRs, industrial equipment, and other applications. The customization process can cover cell configuration, voltage, capacity, BMS, housing, connectors, communication interfaces, and mechanical structure.

This guide explains the differences between 24V, 36V, and 48V robot batteries and the technical factors that should be considered before selecting a battery pack.

1. What Does Robot Battery Voltage Mean?

Battery voltage represents the electrical potential of the battery system.

A lithium battery pack is normally assembled from multiple individual cells connected in series and parallel. The series configuration determines the nominal voltage, while the parallel configuration affects capacity and current capability.

For example, a battery pack can be configured to provide a target voltage and capacity according to the robot’s electrical architecture.

The relationship between voltage, current, and power can be expressed as:

Power (W) = Voltage (V) × Current (A)

If a robot requires approximately 1,000W of electrical power, the theoretical current would be:

Akku-Spannung	Current at 1,000W
24V	Approximately 41.7A
36V	Approximately 27.8A
48V	Approximately 20.8A

These values are simplified calculations. Actual current depends on motor efficiency, controller efficiency, acceleration, mechanical load, operating conditions, and other electrical components.

This relationship is important because the battery pack, BMS, wiring, connectors, fuse, and controller all need to accommodate the required current.

2. 24V Robot Battery

24V battery systems are commonly considered for mobile equipment with relatively moderate power requirements.

Potential applications include:

• Cleaning robots
• Small AGVs
• Serviceroboter
• Inspektionsroboter
• Mobile platforms
• Small warehouse robots
• Autonomous equipment

A 24V lithium battery pack can be designed with different capacities depending on the required operating time and available installation space.

For example, a custom battery pack may be designed around:

• 24V nominal voltage
• Individuell angepasste Ah-Kapazität
• Lithium-ion or LiFePO4 cells
• Customized BMS
• CAN, UART, or RS485 communication
• Kundenspezifische Steckverbinder
• Custom housing
• Überwachung der Temperatur

For compact robots, mechanical design can be as important as electrical specifications. The battery may need to fit underneath the robot, inside a battery compartment, or into a removable battery tray.

Therefore, the available battery space should be measured before the final pack design is confirmed.

3. 36V Robot Battery

36V systems are another option for mobile robots and industrial equipment.

A 36V battery can support equipment designed around a 36V motor and controller system. Applications may include:

• AGVs
• AMRs
• Warehouse robots
• Autonomous cleaning equipment
• Mobile material-handling equipment
• Inspection platforms
• Industrial mobile equipment

When a robot has a defined 36V electrical architecture, the battery pack needs to be designed to match the controller, charger, motor, and other electrical components.

The battery capacity can then be selected according to the required runtime.

Zum Beispiel:

36V × 40Ah = 1,440Wh

This means the nominal battery energy is approximately 1.44kWh.

Actual usable energy depends on the battery chemistry, BMS settings, discharge current, temperature, operating conditions, and other system factors.

4. 48V Robot Battery

48V battery systems are commonly used in equipment where the electrical architecture requires a 48V-class battery.

Potential applications include:

• Industrial AGVs
• AMRs
• Warehouse robots
• Material-handling robots
• Autonomous transport equipment
• Heavy-duty mobile platforms
• Industrial cleaning machines

At the same power level, a higher system voltage can reduce the current required by the electrical system.

Zum Beispiel:

48V × 50A = 2,400W

This relationship is useful when engineers are designing the motor, controller, wiring, connectors, and battery pack as a complete system.

However, the battery voltage must always match the electrical architecture of the robot. A 48V battery should not simply be installed in a system designed for another voltage without confirming compatibility with the motor controller, charger, BMS, and other components.

5. 24V vs 36V vs 48V Robot Battery

The three voltage systems can be compared from an engineering perspective.

Factor	24V	36V	48V
Typical system use	Small and medium mobile equipment	AGV, AMR and mobile equipment	Industrial mobile equipment
Current at the same power	Höher	Mittel	Nach unten
Motor compatibility	Depends on system design	Depends on system design	Depends on system design
BMS design	Load-dependent	Load-dependent	Load-dependent
Capacity options	Custom	Custom	Custom
Kommunikation	CAN/UART/RS485 options	CAN/UART/RS485 options	CAN/UART/RS485 options
Housing	Custom	Custom	Custom
Anschluss	Custom	Custom	Custom

There is no single voltage that applies to every robot.

The correct selection should start with the robot’s electrical architecture rather than the battery itself.

6. How to Calculate Robot Battery Capacity

Voltage alone does not determine how long a robot can operate.

Battery energy can be estimated using:

Energie (Wh) = Spannung (V) × Kapazität (Ah)

Zum Beispiel:

• 24V × 50Ah = 1,200Wh
• 36V × 50Ah = 1,800Wh
• 48V × 50Ah = 2,400Wh

If a robot consumes an average of 600W, a simplified runtime calculation for a 48V 50Ah battery would be:

2,400Wh ÷ 600W = 4 hours

This is a theoretical calculation rather than a guaranteed operating time.

Actual robot runtime can be affected by:

• Motorlast
• Nutzlast
• Driving speed
• Acceleration and braking
• Floor conditions
• Inclines
• Operating cycle
• Batterietemperatur
• Battery discharge rate
• Controller efficiency
• Motoreffizienz
• BMS cutoff settings
• Usable depth of discharge

For OEM projects, runtime testing under real operating conditions is recommended.

7. Peak Current Is Important for Robot Battery Design

Robot batteries are not exposed to a constant load in many applications.

During acceleration, climbing, turning, starting, or carrying a heavy load, the motor can temporarily require significantly more current than during steady movement.

Therefore, battery design should consider both:

Kontinuierlicher Entladestrom

und

Spitzenableitstrom

For example, a robot might require:

• 30A continuous current
• 60A peak current

The BMS, cells, wiring, connectors, fuse, and protection system should be selected according to these requirements.

A battery pack with sufficient Ah capacity may still be unsuitable if its discharge capability does not meet the robot’s peak current demand.

This is one reason why battery capacity alone should not be used to evaluate a robot battery design.

8. BMS Requirements for Robot Battery Packs

The Battery Management System is an important part of a customized robot battery pack.

A BMS can monitor and manage parameters such as:

• Zellspannung
• Pack-Spannung
• Aktuell
• Temperatur
• Ladezustand
• Ladezustand
• Discharging status

Depending on the application, protection functions can include:

• Schutz vor Überladung
• Schutz vor Überentladung
• Überstromschutz
• Kurzschlussschutz
• Schutz vor Überhitzung
• Under-temperature protection
• Zellausgleich

Industrial robots may also require communication between the battery and the main controller.

Zu den gängigen Kommunikationsmöglichkeiten gehören:

CAN

UART

RS485

The communication protocol should be defined during the battery design stage because the BMS firmware, connector, wiring, and controller interface may all depend on the selected protocol.

9. Lithium-Ion vs LiFePO4 for Robot Batteries

Both lithium-ion and LiFePO4 battery technologies can be considered for robot applications.

Lithium-Ion Battery Packs

Lithium-ion cells can be considered when the project has strict requirements for:

• Batteriegröße
• Gewicht
• Energiekapazität
• Compact mechanical design

The specific cell type should be selected according to voltage, capacity, current, cycle requirements, temperature range, and available installation space.

LiFePO4-Akkupacks

LiFePO4 is frequently considered for industrial applications where the project requires:

• Frequent charge and discharge
• Long operating cycles
• Stabile thermische Eigenschaften
• Industrial-duty operation

The choice between lithium-ion and LiFePO4 should be based on the complete application requirements rather than battery chemistry alone.

10. Robot Battery Size and Mechanical Design

Electrical specifications are only one part of battery customization.

A robot battery also needs to physically fit the equipment.

Important mechanical parameters include:

• Länge
• Breite
• Höhe
• Gewicht
• Mounting holes
• Battery tray
• Handle
• Anschlussposition
• Cable exit direction
• Housing material
• Protection requirements
• Ventilation requirements

For removable robot batteries, the pack may also require a quick-release mechanism or dedicated battery mounting structure.

For fixed installations, the housing may be designed around the available internal space.

This is particularly important for AGV and AMR applications because battery placement can affect weight distribution, center of gravity, maintenance access, and available space for other components.

11. Charging Requirements

The battery charger must match the battery pack.

The charging system should be evaluated according to:

• Chemie der Batterie
• Pack-Spannung
• Ladespannung
• Ladestrom
• BMS-Anforderungen
• Anschluss
• Charging communication
• Ladetemperatur
• Aufladezeit

For example, a 24V-class battery and a 48V-class battery require different charging systems.

The charging profile also depends on the selected cell chemistry and battery configuration.

For robots operating continuously in warehouses or factories, charging strategy can be an important part of the overall battery system design.

Depending on the equipment, the project may use:

• Standard charging
• Schnelles Laden
• Automatic charging
• Docking-station charging
• Removable battery replacement

The battery supplier should confirm charging parameters during the design stage.

12. How to Choose Between 24V, 36V and 48V

The selection process can be organized into several steps.

Step 1: Confirm the Motor Voltage

Check the rated voltage of the motor and motor controller.

The battery voltage should be compatible with the complete drive system.

Step 2: Determine Power Consumption

Calculate the robot’s continuous and peak power requirements.

This provides the basis for estimating current requirements.

Step 3: Determine Required Runtime

Estimate how many hours the robot needs to operate between charging cycles.

Then calculate the required battery energy.

Step 4: Check Installation Space

Measure the available battery compartment.

A battery specification that cannot fit the equipment cannot be used without mechanical changes.

Step 5: Define Peak Current

Determine the current required during:

• Startup
• Beschleunigung
• Klettern
• Heavy loading
• Drehen
• Emergency operation

Step 6: Select Battery Chemistry

Evaluate lithium-ion and LiFePO4 according to energy density, cycle requirements, operating temperature, weight, dimensions, and application conditions.

Step 7: Define BMS Functions

Specify:

• Schutzfunktionen
• Current rating
• Temperatursensoren
• SOC estimation
• Kommunikationsprotokoll
• Data requirements

Step 8: Confirm Testing Requirements

Before mass production, the battery should be evaluated according to the application’s technical requirements.

Testing may include capacity testing, charge/discharge testing, BMS protection testing, voltage consistency testing, aging testing, temperature testing, vibration testing, and communication testing.

13. What Information Should You Give a Robot Battery Manufacturer?

For a custom robot battery project, providing complete technical information can make the design process more efficient.

A battery manufacturer may need:

1. Robot application
2. Robot model
3. Motorleistung
4. Required battery voltage
5. Required capacity
6. Continuous current
7. Peak current
8. Target runtime
9. Ladeverfahren
10. Verfügbarer Einbauraum
11. Battery weight requirement
12. Steckertyp
13. Kommunikationsprotokoll
14. Betriebstemperatur
15. Waterproof or dustproof requirements
16. Sample quantity
17. Estimated annual quantity

Photos, drawings, existing battery samples, wiring diagrams, and equipment specifications can also help engineers understand the project.

14. Custom Robot Battery Pack OEM/ODM Process

For OEM and ODM projects, battery development normally involves several stages.

Requirement Analysis

The engineering team reviews the robot’s electrical, mechanical, environmental, and communication requirements.

Battery Configuration

The cell configuration is developed according to voltage, capacity, current, and available space.

BMS Design

The BMS is selected or customized according to protection requirements, current requirements, temperature monitoring, and communication.

Structural Design

The battery housing, mounting structure, connector position, cable routing, and other mechanical details are developed.

Prototype

Prototype battery packs are produced for installation and functional testing.

Testen

The battery undergoes electrical, mechanical, thermal, and communication tests according to the project requirements.

Massenproduktion

After the prototype is approved, the production process can move to the required batch size.

Dongguan Yizhan Electronics Technology Co., Ltd. supports customized lithium battery pack development from R&D and design through sampling and mass production. Custom options can include battery voltage, capacity, BMS, connectors, cables, housing, labels, and other structural requirements.

15. Robot Battery Testing and Quality Control

A robot battery needs to operate as part of a complete equipment system.

Testing can therefore include both battery-level and application-related evaluations.

Typical battery tests include:

• Kapazitätstest
• Charge test
• Discharge test
• Voltage consistency test
• Prüfung des Innenwiderstands
• BMS protection test
• Over-current test
• Short-circuit protection test
• Temperature protection test
• Alterungstest
• Kommunikationstest

For mobile robots, mechanical testing can also be considered.

Depending on the application, vibration and impact conditions may need to be evaluated because robots can operate on warehouse floors, ramps, uneven surfaces, or industrial environments.

Environmental requirements such as dust and water protection should also be defined during the design stage.

16. 24V, 36V or 48V: Start With the Robot, Not the Battery

The choice between 24V, 36V, and 48V should be based on the robot’s complete power system.

Ein praktisches Auswahlverfahren sieht wie folgt aus:

Robot → Motor → Controller → Power Requirement → Battery Voltage → Capacity → BMS → Mechanical Design → Testing

For example, if the robot is designed around a 24V motor controller, changing to a 48V battery is not simply a matter of installing a battery with twice the voltage.

The controller, motor, charger, wiring, connectors, BMS, protection system, and other electrical components may all require compatibility checks.

For this reason, custom battery development should begin with the equipment specifications.

17. Custom Robot Battery Solutions From Dongguan Yizhan

Dongguan Yizhan Electronics Technology Co., Ltd. develops customized lithium battery packs for robot and industrial equipment applications.

The company supports OEM and ODM battery projects involving:

• Robot battery packs
• AGV-Batterien
• AMR batteries
• Cleaning robot batteries
• Industrial equipment batteries
• Li-ion battery packs
• LiFePO4-Akkus
• Benutzerdefiniertes BMS
• CAN-Kommunikation
• UART-Kommunikation
• RS485-Kommunikation

Customization can cover voltage, capacity, cell configuration, BMS, housing, connector, cable, labeling, and mechanical structure.

For a new robot battery project, customers can provide the equipment model, motor power, target voltage, capacity requirement, current requirement, installation dimensions, runtime target, and communication requirements. The engineering team can then use these parameters to develop the battery configuration and technical proposal.

FAQ

Is 24V or 48V better for a robot battery?

There is no universal voltage for all robots. The required voltage depends on the robot’s motor, controller, power architecture, current requirements, and application conditions.

Can I replace a 24V robot battery with a 36V battery?

Not without checking system compatibility. The motor controller, motor, charger, BMS, wiring, and other electrical components need to support the new voltage.

How do I calculate robot battery capacity?

Use the basic formula:

Batterieenergie (Wh) = Spannung (V) × Kapazität (Ah)

The required capacity should then be adjusted according to actual power consumption, runtime, usable battery energy, temperature, and operating conditions.

What BMS is suitable for an AGV battery?

The BMS should be designed according to the battery cell configuration, continuous current, peak current, temperature requirements, protection functions, and communication protocol.

Can robot battery packs be customized?

Yes. Custom robot battery packs can be developed according to voltage, capacity, dimensions, current, BMS, connector, communication, housing, and other equipment requirements.

Can Yizhan manufacture both 24V and 48V robot batteries?

Customized battery configurations can be developed according to the electrical and mechanical requirements of the target equipment. The final configuration should be confirmed through the robot’s technical specifications.

Schlussfolgerung

Selecting a robot battery is not simply a choice between 24V, 36V, and 48V.

The correct battery configuration needs to match the robot’s motor, controller, power consumption, operating time, continuous and peak current, installation space, charging system, BMS, communication protocol, and environmental requirements.

For OEM and ODM projects, a customized battery pack can integrate these requirements into one system, covering cell selection, electrical configuration, BMS, mechanical structure, connectors, communication, testing, and production.

For robot developers, AGV manufacturers, AMR manufacturers, and industrial equipment companies, providing complete equipment specifications at the beginning of the project can help battery engineers develop a suitable power solution.

Dongguan Yizhan Electronics Technology Co., Ltd. supports customized lithium battery pack development for robot and industrial applications, from requirement analysis and design to prototype development, testing, and mass production.